Cooling system

Abstract

A cooling system including a first sheet steel item having a first surface configured to accommodate one or more objects to be cooled, and a second surface joined to a first surface of a second sheet steel item forming a shell. The items may be joined by a weld, a rivet or a plurality thereof. At least one of the second surface of the first sheet steel item and the first surface of the second sheet steel item may be formed to produce one or more conduits for forming one or more channels, whereby said joining forms said channels for coolant in a space between the second surface of the first sheet steel item and the first surface of the second sheet steel item.

The invention claimed is: 
     
       1. A cooling system comprising:
 a first sheet steel item having a first surface configured to accommodate one or more objects to be cooled, and a second surface; and 
 a second sheet steel item forming a shell, 
 wherein the second surface of the first sheet steel item is joined to a first surface of the second sheet steel item, and 
 at least one of the second surface of the first sheet steel item and the first surface of the second sheet steel item have been formed to produce one or more conduits for forming one or more channels, whereby said joining forms said channels for coolant in a space between the second surface of the first sheet steel item and the first surface of the second sheet steel item, said channels comprising:
 one or more inlet manifolds for coolant, 
 a number of outlet manifolds for coolant, wherein the number of outlet manifolds is equal to one more than the number of inlet manifolds, 
 
 whereby each channel is connected to one or more inlet manifolds and one or more outlet manifolds, and 
 wherein the conduits comprise bends, an outer side and an inner side of each conduit each have a first radius of curvature in a crossflow direction in an upstream end of the bend and a second radius of curvature in a crossflow direction in a downstream end of the bend, the first radius of curvature of the outer side is larger than the second radius of curvature of the outer side and the first radius of curvature of the inner side is larger than the second radius of curvature of the inner side, and a curvature of the outer side and a curvature of the inner side of each conduit are each asymmetrical about a longitudinal axis of the bend. 
 
     
     
       2. The cooling system according to  claim 1 , wherein the inlet manifolds are positioned in a longitudinal centre between the first sheet steel item and the second sheet steel item. 
     
     
       3. The cooling system according to  claim 1 , wherein the first sheet steel item and/or the second sheet steel item comprise austenitic stainless steel. 
     
     
       4. The cooling system according to  claim 1 , wherein the first surface of the first sheet steel item is configured to accommodate one or more objects to be cooled selected from the group consisting of individual battery modules, battery cells, engine components and control units. 
     
     
       5. A method for manufacturing a cooling system according  claim 1 , comprising:
 providing a first sheet steel item comprising an essentially planar area having a first surface configured to accommodate one or more individual objects to be cooled and a second surface, 
 providing a second sheet steel item having a first surface and a second surface, 
 forming at least one of the first and second sheet steel items to produce a pattern of conduits, 
 joining the first surface of the second sheet steel item to the second surface of the first sheet steel item, thereby forming channels for a cooling fluid between the sheet steel items. 
 
     
     
       6. The method according to  claim 5 , wherein the objects to be cooled are selected from the group consisting of individual battery modules, battery cells, engine components and control units. 
     
     
       7. A battery compartment of an electric drive vehicle comprising a cooling system manufactured according to the method of  claim 5 . 
     
     
       8. A storage system comprising a cooling system manufactured according to the method of  claim 5 . 
     
     
       9. The method according to  claim 5 , comprising deep drawing one or more of the first sheet steel item and the second sheet steel item. 
     
     
       10. The method according to  claim 5 , comprising cold rolling one or more of the first sheet steel item and the second sheet steel item. 
     
     
       11. The method according to  claim 10 , comprising continuously cold rolling the second sheet steel item to produce a repetitive series of conduits. 
     
     
       12. The method according to  claim 10 , further comprising cutting the cold rolled material to length to obtain components for separate cooling systems. 
     
     
       13. The method according to  claim 5 , further comprising forming bends in the channels, said channels having in an outer side as well as in an inner side an enlarged radius in a crossflow direction at an upstream end of the bend. 
     
     
       14. The method according to  claim 5 , wherein the first sheet steel item and/or the second sheet steel item comprise austenitic stainless steel. 
     
     
       15. A battery compartment of an electric drive vehicle comprising a cooling system according to  claim 1 . 
     
     
       16. A storage system for battery modules, battery cells, engine components and/or control units comprising a cooling system according to  claim 1 .